БЛОК ДВИГАТЕЛЯ РАЗБОРКА

Tech Tips

Check whether the engine is TMC made or not by referring to the following illustration.

A01CE8JE01
Text in Illustration
*A for TMC Made Engine *B except TMC Made Engine
*1 Engine Oil Level Dipstick Guide *2 Water Inlet Housing
*3 Water Inlet Housing Drain Cock Assembly - -

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01CDZ4

      Remove the oil filler cap from the cylinder head cover.

  2. REMOVE OIL FILLER CAP GASKET


    1. A01CCSU

      Remove the oil filler cap gasket from the oil filler cap.

  3. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01CG16

      Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.

  4. REMOVE SPARK PLUG


    1. A01CD6B

      Remove the 4 spark plugs.

  5. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Using SST, remove the oil filter sub-assembly.

      SST
      09228-06501

  6. REMOVE ENGINE OIL COOLER (for TMC Made Engine with Engine Oil Cooler)


    1. A01CEU1

      Remove the nut, oil cooler union and oil cooler.

  7. REMOVE OIL FILTER UNION (except TMC Made Engine with Engine Oil Cooler)


    1. A01CBGC

      Using a 12 mm socket hexagon wrench, remove the oil filter union.

  8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CBEPE03
      Text in Illustration
      *1 Nut

      Remove the 8 bolts and 2 nuts, and remove the cylinder head cover.

  9. REMOVE CYLINDER HEAD COVER GASKET


    1. A01CDI6

      Remove the cylinder head cover gasket from the cylinder head cover.

  10. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01CG6C

      Remove the 3 bolts and engine mounting bracket RH.

  11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01CBYZ

      Remove the bolt, nut and belt tensioner.

  12. REMOVE CRANK POSITION SENSOR (for TMC Made Engine)


    1. A01CCT1

      Disconnect the connector from the connector bracket.

    2. Disconnect the 2 wire harness clamps.

    3. Remove the bolt and crank position sensor.

  13. REMOVE CRANK POSITION SENSOR (except TMC Made Engine)


    1. A01CG06

      Disconnect the connector from the connector bracket.

    2. Disconnect the wire harness clamp.

    3. Remove the bolt and crank position sensor.

  14. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CDR8

      Remove the bolt and camshaft position sensor.

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CAPME19
      Text in Illustration
      *1 Timing Mark
      *2 Paint Mark
      *3 Groove

      Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.

    2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      If not, turn the crankshaft pulley 1 revolution (360°) to align the timing marks as illustrated.

    3. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.

  16. REMOVE CRANKSHAFT PULLEY


    1. A01CG29E02

      Using SST, hold the crankshaft pulley in place and loosen the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01CG1RE01

      Using SST, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      09950-40011   ( 09957-04010 )

      Tech Tips

      If necessary, remove the pulley and pulley bolt using SST.

  17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01CFD7

      Remove the bolt and camshaft timing oil control valve from the cylinder head.

      Note

      The camshaft timing oil control valve may be damaged when loosening the cylinder head bolts if it is not removed.

    2. Remove the O-ring from the camshaft timing oil control valve.

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01CCBI

      Remove the 2 nuts, No. 1 chain tensioner assembly and gasket.

      Note

      Do not turn the crankshaft without the No. 1 chain tensioner assembly.

  19. REMOVE WATER PUMP PULLEY


    1. A01CBGYE03

      Using SST, remove the 4 bolts and water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

  20. REMOVE WATER PUMP ASSEMBLY (for TMC Made Engine)


    1. A01CBBLE01

      Remove the clamp of the crankshaft position sensor from the water pump.

    2. Disconnect the wire of the crankshaft position sensor from the clamp bracket.

    3. A01CAL5E05
      Text in Illustration
      *1 Clamp Bracket

      Remove the 4 bolts, 2 nuts and clamp bracket.

    4. A01CFKA

      Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the water pump and cylinder block.

  21. REMOVE WATER PUMP ASSEMBLY (except TMC Made Engine)


    1. A01CD7LE02
      Text in Illustration
      *1 Clamp Bracket

      Disconnect the connector of the crankshaft position sensor.

    2. Disconnect the wire of the crankshaft position sensor from the clamp brackets.

    3. A01CD6YE03
      Text in Illustration
      *1 Clamp Bracket

      Remove the 4 bolts, 2 nuts and 2 clamp brackets.

    4. A01CFI4

      Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the water pump and cylinder block.

  22. REMOVE OIL PAN DRAIN PLUG


    1. A01CCT0

      Remove the oil pan drain plug and gasket from the oil pan.

  23. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01CCS7

      Remove the 12 bolts and 2 nuts.

    2. A01CCX8

      Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.

      Note

      Be careful not to damage the contact surfaces of the crankcase, chain cover or oil pan.

  24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01CG6C

      Remove the 3 bolts and engine mounting bracket RH.

    2. A01CFE9

      Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

    3. A01CFL9E06

      Remove the 12 bolts and 2 nuts.

    4. A01CDPXE02
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01CB9XE02
      Text in Illustration
      *1 Protective Tape

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01CCI8

      Remove the No. 1 crankshaft position sensor plate.

  27. REMOVE TIMING CHAIN GUIDE


    1. A01CFN4E01

      Remove the bolt and timing chain guide.

  28. REMOVE CHAIN TENSIONER SLIPPER


    1. A01CBW1

      Remove the bolt and chain tensioner slipper.

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01CEP1

      Remove the 2 bolts and No. 1 chain vibration damper.

  30. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  31. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01CC5L

      Remove the crankshaft timing gear or sprocket from the crankshaft.

  32. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01CFVIE04
      Text in Illustration
      *1 Groove

      Turn the crankshaft 90° counterclockwise to align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

    2. A01CCR5E04
      Text in Illustration
      *1 Groove

      Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

    3. A01CEZ9E07
      Text in Illustration
      *1 Bolt
      *2 Chain Tensioner Plate
      *3 Spring

      Remove the bolt, chain tensioner plate and spring.

    4. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.

  33. REMOVE KEYS


    1. A01CEWS

      Remove the 2 pulley set keys from the crankshaft.

  34. REMOVE NO. 2 CAMSHAFT


    1. A01CEB0E11

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.

    3. Remove the No. 2 camshaft.

  35. REMOVE CAMSHAFT


    1. A01CG41E04

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.

    3. Remove the camshaft.

  36. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01CAPV

      Remove the camshaft bearing from the No. 1 camshaft bearing cap.

  37. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01CG0N

      Remove the No. 2 camshaft bearing from the cylinder head.

  38. REMOVE NO. 2 CAMSHAFT TIMING SPROCKET


    1. A01CFMHE01

      Clamp the camshaft in a vise.

      Note


      • Do not overtighten the vise.

      • Do not damage the camshaft.

    2. Remove the bolt and camshaft timing gear or sprocket.

  39. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01CCKFE08
      Text in Illustration
      *1 Vinyl Tape
      *2 Rubber
      *a Advance Side Path
      *b Close
      *c Open

      Clamp the camshaft in a vise, and make sure that the camshaft timing gear assembly does not rotate.

    2. Cover all the oil path with vinyl tape except the advance side path shown in the illustration.

    3. A01CE2LE02

      Apply air pressure of 150 kPa (1.5 kgf/cm2, 22 psi) to the oil path, then turn the camshaft timing gear assembly to the advance direction (counterclockwise) by hand.

      CAUTION:

      Cover the paths with a piece of cloth to avoid oil splashes.

      Tech Tips

      Depending on the air pressure, the camshaft timing gear assembly may turn to the advance side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from a path, the lock pin may be difficult to release.

    4. A01CFME

      Remove the flange bolt and camshaft timing gear.

      Note


      • Be sure not to remove the other 4 bolts.

      • When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.

  40. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01CBVRE01

      In several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

      Note

      Head warpage or cracking could result from removing the bolts in the wrong order.

    2. A01CBHH

      Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

      Note

      Be careful not to damage the contact surfaces between the cylinder head and cylinder block.

  41. REMOVE CYLINDER HEAD GASKET

    A01CF3K

  42. REMOVE CYLINDER BLOCK WATER JACKET SPACER (for TMC Made Engine)


    1. A01CCHK

      Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.

      Note

      Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

  43. REMOVE CYLINDER BLOCK WATER JACKET SPACER (except TMC Made Engine)


    1. A01CDYS

      Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.

      Note

      Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

  44. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (for TMC Made Engine without Engine Oil Cooler)


    1. A01CB6JE01

      Remove the water drain cock plug from the water drain cock.

    2. Remove the water drain cock from the stiffening crankcase.

  45. REMOVE WATER INLET HOUSING DRAIN COCK ASSEMBLY (except TMC Made Engine)


    1. A01CC2L

      Remove the water drain cock plug from the water drain cock.

    2. Remove the water inlet housing drain cock from the stiffening crankcase.

  46. REMOVE WATER INLET HOUSING (except TMC Made Engine)


    1. A01CEVWE01

      Uniformly loosen and remove the 5 bolts in the sequence shown in the illustration.

    2. A01CBVJE06
      Text in Illustration
      *1 Water Inlet Housing O-ring
      *2 Water Inlet Housing Gasket

      Remove the water inlet housing O-ring and water inlet housing gasket from the water inlet housing.

  47. REMOVE OIL CONTROL VALVE FILTER


    1. A01CC5DE05
      Text in Illustration
      *1 Oil Filter Control Valve
      *2 Gasket
      *3 Plug

      Using an 8 mm socket hexagon wrench, remove the plug, gasket and oil control valve filter.

  48. REMOVE OIL PUMP ASSEMBLY


    1. A01CBL9E01

      Remove the 3 bolts, oil pump and gasket.

  49. INSPECT BALANCESHAFT THRUST CLEARANCE


    1. Install the balanceshafts Click here.

    2. A01CEDB

      Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.

  50. REMOVE BALANCESHAFT HOUSING


    1. A01CFLUE01

      Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

    2. Remove the balanceshaft housing from the crankcase.

      Tech Tips

      Keep the lower bearing and balanceshaft housing together.

  51. REMOVE NO. 1 AND NO. 2 BALANCESHAFTS


    1. A01CEHME06
      Text in Illustration
      *1 No. 1
      *2 No. 2
      *3 Timing Mark

      Remove the No. 1 and No. 2 balanceshafts.

  52. REMOVE NO. 1 BALANCESHAFT BEARING


    1. A01CAKUE12
      Text in Illustration
      *1 Stiffening Crankcase
      *2 Balance Shaft Housing

      Remove the 8 No. 1 balanceshaft bearings shown in the illustration.

  53. INSPECT BALANCESHAFT OIL CLEARANCE


    1. Clean each bearing and journal.

    2. Check each bearing and journal for pitting and scratches.

      If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft.

    3. Place the No. 1 and No. 2 balanceshafts onto the crankcase.

    4. A01CFQRE02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each journal.

    5. Install the balanceshaft housing Click here.

      Note

      Do not turn the balanceshafts.

    6. Remove the balanceshafts Click here.

    7. A01CDOVE03
      Text in Illustration
      *1 Plastigage

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.022 to 0.049 mm (0.000866 to 0.00193 in.)
      Maximum oil clearance
      0.049 mm (0.00193 in.)

      Note

      Remove the Plastigage completely after the measurement.

      If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balanceshaft.

    8. A01CAW0E02
      Text in Illustration
      *a Number Mark
      *b Front No. 1 Journal Bore
      *c Rear No. 1 Journal Bore
      *d Front No. 2 Journal Bore
      *e Rear No. 2 Journal Bore

      If replacing a bearing, select a new one with the same number.

      Standard Balanceshaft Housing Journal Bore Diameter
      Item Specified Condition
      Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.)
      Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.)
      Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.)
      Standard Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.486 to 1.489 mm (0.05850 to 0.05862 in.)
      Mark 2 1.490 to 1.492 mm (0.05866 to 0.05874 in.)
      Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.)
      Standard balanceshaft journal diameter
      22.985 to 23.000 mm (0.9049 to 0.9055 in.)

    9. Inspect the balanceshaft housing bolts.


      1. A01CG42E05
        Text in Illustration
        *a Measurement Length

        Using a vernier caliper, measure the length of the bolts from the seat to the end.

        Standard bolt length
        58.3 to 59.7 mm (2.295 to 2.350 in.)
        Maximum bolt length
        60.3 mm (2.374 in.)

        If the bolt length is greater than the maximum, replace the balanceshaft housing bolt.

  54. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01CEIBE09
      Text in Illustration
      *1 Protective Tape
      *a Cut Position

      Using a knife, cut off the lip of the oil seal.

    2. Using a screwdriver, pry out the oil seal.

      Note

      After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

      Tech Tips

      Tape the screwdriver tip before use.

  55. REMOVE STIFFENING CRANKCASE ASSEMBLY


    1. A01CCSKE01

      Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

    2. A01CAX2E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the crankcase by prying between the crankcase and cylinder block.

      Note

      Be careful not to damage the contact surfaces between the crankcase and cylinder block.

    3. A01CCHM

      Remove the O-ring from the cylinder block.